Tercel 1995-1996

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



3E-E Engine

CAUTION
The fuel system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  
  3. Remove the gas cap and relieve fuel system pressure.
  4.  
  5. Disconnect the PCV hose from the valve cover.
  6.  
  7. Remove the air intake connector. Disconnect the accelerator cable and throttle cable.
  8.  
  9. Remove the vacuum sensing hose from the pressure regulator.
  10.  
  11. Remove the dash pot and link bracket.
  12.  
  13. Disconnect the fuel inlet and return hoses.
  14.  
  15. Place a towel or container under the cold start injector pipe. Loosen the two union bolts at the fuel line and remove the pipe with its gaskets.
  16.  
  17. Disconnect the injector electrical connections.
  18.  
  19. At the fuel delivery pipe (rail), remove the 2 bolts. Lift the delivery pipe and the injectors free of the engine.
  20.  
  21. Remove the four insulators and 2 collars from the cylinder head.
  22.  
  23. Pull the injectors free of the delivery pipe.
  24.  

To install:

  1. Before installing the injectors back into the fuel rail, install a NEW O-ring on each injector.
  2.  
  3. Coat each O-ring with a light coat of gasoline and alternately install the injectors into the delivery pipe, dark blue injector then a brown injector, dark blue injector, brown injector.
  4.  
  5. Make certain each injector can be smoothly rotated. If they do not rotate smoothly, the O-ring is not in its correct position.
  6.  
  7. Install the insulators into each injector hole. Place the 2 spacers on the delivery pipe mounting holes in the cylinder head.
  8.  
  9. Place the delivery pipe and injectors on the cylinder head and again check that the injectors rotate smoothly. Install the bolts and tighten them to 14 ft. lbs. (19 Nm).
  10.  
  11. Connect the electrical connectors to each injector.
  12.  
  13. Install two new gaskets and attach the inlet pipe and fuel union bolt. Tighten the bolt to 22 ft. lbs. (30 Nm). Install the mounting bolt.
  14.  
  15. Install new gaskets and connect the cold start injector pipe to the delivery pipe and cold start injector. Install the fuel line union bolts and tighten them to 13 ft. lbs. (17 Nm).
  16.  
  17. Connect the fuel return hose and the vacuum sensing hose to the pressure regulator. Attach the PCV hose to the valve cover.
  18.  
  19. Reconnect the accelerator cable, throttle cable and install the air intake connector. Install the dash pot and link bracket.
  20.  
  21. Connect the negative battery terminal. Start the engine and check for leaks.
    CAUTION
    If there is a leak at any fitting, the line will be under pressure and the fuel may spray in a fine mist. This mist is extremely explosive. Shut the engine off immediately if any leakage is detected. Use rags to wrap the leaking fitting until the pressure diminishes and wipe up any fuel from the engine area.



    Click image to see an enlarged view

    Fig. Make certain each injector can be smoothly rotated once installed

  22.  

5E-FE Engine
Distributor Ignition

Specific to:

Toyota Tercel 1995

  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the negative battery cable from the battery. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  4.  
  5. Remove the PCV hose.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector and rail assembly-5E-FE engine

  6.  
  7. Disconnect the vacuum hose from the fuel pressure regulator.
  8.  
  9. Disconnect the fuel return hose and the delivery hose. Catch any fuel with a shop towel.
  10.  
  11. Remove the accelerator cable bracket and disconnect the four (4) injector connectors.
  12.  
  13. Remove the intake air chamber support bracket.
  14.  
  15. Remove the two (2) delivery pipe bolts and remove the delivery pipe with the injectors, being careful not to drop the injectors. Note the positions of the spacers for installation.
  16.  

To install:

  1. Install the injectors with new O-rings with the delivery pipe. Coat the new O-rings with gasoline. Make sure the injectors can be rotated by hand once they are installed.
  2.  
  3. Install the two (2) pipe bolts and torque them to 14 ft. lbs. (19 Nm).
  4.  
  5. Install the air intake chamber bracket and torque to 13 ft. lbs. (17 Nm).
  6.  
  7. Install the injector connectors in their original positions, then install the accelerator bracket.
  8.  
  9. Connect the inlet hose to the delivery pipe, using new gaskets, and torque the union bolt to 22 ft. lbs. (29 Nm).
  10.  
  11. Connect the return hose to the return pipe.
  12.  
  13. Connect the vacuum hose to the regulator.
  14.  
  15. Install the PCV hose and connect the negative battery cable.
  16.  
  17. Start the engine and check for leaks.
  18.  

Distributorless Ignition

Specific to:

Toyota Tercel 1996

  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the negative battery terminal. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  4.  
  5. Disconnect the vacuum hose from the fuel pressure regulator.
  6.  
  7. Disconnect the engine wire clamp from the No. 2 engine hanger.
  8.  
  9. Disconnect the fuel return hose and the delivery hose and catch the spilled fuel with a shop towel.
  10.  
  11. Disconnect the engine wire from the surge tank stay.
  12.  
  13. Disconnect the 4 injector connectors.
  14.  
  15. Remove the 2 delivery pipe bolts and remove the delivery pipe with the injectors, being careful not to drop the injectors. Note the positions of the spacers for installation.
  16.  

To install:

  1. Install the injectors with new O-rings with the delivery pipe. Coat the new O-rings with gasoline. Make sure the injectors can be rotated by hand once they are installed.
  2.  
  3. Install the two (2) pipe bolts and torque them to 14 ft. lbs. (19 Nm).
  4.  
  5. Install the air intake chamber bracket and torque to 13 ft. lbs. (17 Nm).
  6.  
  7. Install the injector connectors in their original positions, then install the accelerator bracket.
  8.  
  9. Connect the inlet hose to the delivery pipe, using new gaskets, and torque the union bolt to 22 ft. lbs. (29 Nm).
  10.  
  11. Connect the return hose to the return pipe.
  12.  
  13. Connect the vacuum hose to the regulator.
  14.  
  15. Connect the engine wire clamp to the No. 2 engine hanger.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Start the engine and check for leaks.
  20.  

 
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